Propane Refrigeration System: Operations and Maintenance

Introduction:

This Propane Refrigeration System, Operations, and Maintenance training unit is designed to introduce trainees to some of the basic principles of refrigeration system operation and provide a detailed explanation of mechanical refrigeration system cycle components (surge drum, expansion valve, chiller, refrigeration compressor, and condenser).

Participants in this Propane Refrigeration System, Operations, and Maintenance course will explore conducting design, operation, control systems, maintenance, efficiency improvement, and troubleshooting refrigeration systems for natural gas processing. After completing this propane refrigeration unit, trainees should have knowledge and real experience in the natural gas propane refrigeration system and plants.

Propane refrigeration encompasses a complex process most effectively understood when visualized through a system diagram. This Propane Refrigeration System, Operations, and Maintenance course offers detailed explanations paired with diagrams illustrating the flow and components of the refrigeration cycle, allowing participants to grasp the intricate workings of propane refrigeration units and packages thoroughly.

Course Objectives:

At the end of this Propane Refrigeration System, Operations, and Maintenance course, the participants will be able to:

• Understand propane refrigeration properties.
• Analyze heat transfer factors' impact.
• Design a propane refrigeration system.
• Operate a propane refrigeration system.
• Manage the control system of a propane refrigeration system.
• Maintain a propane refrigeration system.
• Improve the efficiency of a propane refrigeration system.
• Troubleshoot a propane refrigeration system.

Targeted Groups:

• Operation engineers.
• Operation supervisors.
• Process engineers.
• Maintenance engineers.
• Maintenance supervisors.
• Managers and team leaders.
• Design engineers.
• Operators and senior operators.

Targeted Competencies:

Participants competencies in this Propane Refrigeration System, Operations, and Maintenance training will:

• System Understanding and Design Principles.
• Operational Efficiency and Safety Protocols.
• Maintenance and Troubleshooting Techniques.
• Component Inspection and Diagnostics.
• Energy Optimization Strategies.
• Regulatory Compliance and Standards.
• Environmental Impact Management.
• Risk Assessment and Hazard Mitigation.
• Emergency Response and Incident Management.

Course Outlines:

Unit 1: Fundamentals:

• Introduction to Refrigeration.
• Refrigerator propane properties.
• Heat Transfer.
• Refrigeration Systems.
• Basic Refrigeration Cycle.
• Refrigeration Components.
• Secondary Cooling Systems.

Unit 2: Design, Operation, and Control of Propane Refrigeration System Components Cycle:

• Overview of typical single and multi-stage propane refrigeration systems.
• Propane surge drum and pump loading.
• Expansion valves in the propane refrigeration process.
• Propane chillers, including their role and functioning within the refrigeration cycle.
• Economizers and their contribution to the efficiency of the propane refrigeration process.
• Detailed analysis of propane condensers within refrigeration systems.

Unit 3: Propane Refrigeration Centrifugal Compressor:

• Introduction to Centrifugal Compressor Principles.
• Exploring typical Centrifugal Compressors in propane refrigeration.
• In-depth understanding of Centrifugal Compressor Operation.
• Discussion on Multi-Stage Compressors and Axial Compressors.
• Details of Compressor structure, including Casings, Rotors, and Guide Vanes.
• Breakdown of Diffuser and Volute, Diaphragms, and Shaft Seals.
• Compressor parts like Shaft Bearings, Lubrication Systems, and Seal Oil Systems.
• Cooling System fundamentals, along with Drivers, Couplings, and Controls.
• Insights into Compressor Performance, Surge Control, Safety Devices, and Classification.

Unit 4: Propane Refrigeration Reciprocating Compressor:

• Introduction to Reciprocating Compressor Principles.
• Gas Compression and its applications in propane refrigeration systems.
• Identifying typical Compressors suited for propane refrigeration.
• Piston Operation and typical Reciprocating Compressor mechanisms.
• Discussion on Compression Unit Components and operational considerations.
• Review of Compressor valves, air cooling, and water cooling techniques.
• The Cylinder and Compression Unit Lubrication.
• Information on Wiper or Scraper Rings, Clearance Pockets, and Unloaders.
• Insights into the Drive Unit, Crank Assembly, Crosshead, and Connecting Rod.
• Review of Power Sources, Balanced-Opposed, Integral, and Multi-Stage Units.

Unit 5: Propane Refrigeration Troubleshooting and Improve Efficiency:

• Assessing indicators and checks essential for proper functioning.
• Emphasizing operating checks to ensure system reliability.
• Understanding operating problems and their resolutions.
• Learning about Refrigeration System Controls and Applications.
• Factors Affecting operation and methods to tackle issues.
• Solving Fouling problems in propane refrigeration units.
• Implementing maintenance types and creating a maintenance plan.